Low leakage electrical joints and wire harnesses, and method of making the same

ABSTRACT

Low leakage electrical joints and wire harnesses for simplifying the electrical infrastructure associated with solar energy utilities are disclosed. The low leakage electrical joints include fused wires that have been sealed, encased and configured to plug into other joints to form wire harnesses. The wire harnesses are particularly well suited for coupling a plurality of solar collector junction boxes to a combiner box.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of, and claims thebenefit of U.S. application Ser. No. 14/057,089 having a filing date ofOct. 18, 2013, which is a divisional of U.S. application Ser. No.12/502,395, having a filing date of Jul. 14, 2009, that issued as U.S.Pat. No. 8,604,342 on Dec. 10, 2013.

BACKGROUND

(1) Field

The present invention relates generally to electrical components and,more particularly, to low leakage electrical joints and wire harnessesfor simplifying the electrical infrastructure associated with solarenergy utilities. The low leakage electrical joints include fused wiresthat have been sealed, encased and configured to plug into other jointsto form wire harnesses.

(2) Related Art

The problems associated with the world's dependence on non-renewableresources have resulted in increased attention to so-called alternativeenergy, such as solar and wind power. As a result, small-scaleproduction of alternative energy, for example by installing residentialsolar heaters or wind turbines, has become more popular. While theseactions may provide psychological and possible long-term financialbenefits, their actual effect on society's consumption of non-renewableresources is minimal. In short, permanent and significant changesnecessitate the implementation of alternative energy generation on alarge-scale utility basis.

Utility scale production of solar energy, however, is often consideredfinancially imprudent given the high cost of materials, know-how, andlabor. For example, conventionally wiring solar panels typicallyrequires a qualified electrician to measure, cut, connect and crimpwires on site, by hand, between each individual solar panel's junctionbox and the combiner box, and the combiner box and master fuse box. Inaddition, this extensive wiring often further requires the labor andexpense of troubleshooting and repairing.

In addition, conventional solar utility infrastructures often havetechnical shortcomings that further drive up the price. For example,conventional wire connections leak precious energy, thereby decreasingthe efficiency, and increasing the price, of the system.

Accordingly, the interests of being environmentally responsible oftenconflict with the financial realities of building and maintaining asolar energy plant.

Thus, there remains a need for components for use in solar plants thatdecrease the materials, know-how and/or labor associated with buildingand maintaining the electrical infrastructure.

There also remains a need for components for use in solar plants thatdecrease the cost associated with the materials, know-how and/or laborin building and maintaining the electrical infrastructure of a solarplant.

A need also exists for components that decrease electrical leakage.Ideally, these low leakage components are relatively simple, safe andinexpensive to manufacture, transport and use.

A method of making the aforementioned components is also needed.

SUMMARY OF THE INVENTIONS

The present inventions are directed to low leakage electrical joints andwire harnesses for simplifying the electrical infrastructure associatedwith solar energy utilities. The low leakage electrical joints includeinsulated photovoltaic wire which has been partially stripped, with theportion of exposed wire welded to a portion of exposed wire on another,separate photovoltaic wire. The section encompassing the exposed wireand weld is coated in a synthetic rubber sealant and allowed to cure.After curing, the section of exposed/fused/sealed wire is encased in amolded polypropylene material including a UV stabilizing agent.

These resulting joints can be shaped as T's, crosses or Y's, and befitted with various lengths of insulated wire, female connectors and/ormale connectors for attachment to at least one other joint. Wireharnesses can be assembled using a plurality of these joints, usuallywith lengths of insulated wire there between. The nature of the presentinventions will become apparent to those skilled in the art afterreading the following description of the preferred embodiment whenconsidered with the drawings.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 schematically represents the electrical infrastructure of a solarenergy system;

FIG. 2 illustrates a wire harness, including enlarged male and femaleconnectors;

FIG. 3 is a front view of a tee joint;

FIG. 4 is a front view of a cross joint;

FIG. 5 is a front view of a y joint;

FIG. 6 is a perspective view of a tee joint encasement;

FIG. 7 is a perspective view of a cross joint encasement;

FIG. 8 is a perspective view of a y joint encasement; and

FIG. 9 depicts some steps in constructing a tee joint.

Description of the Preferred Embodiments

In the following description, like reference characters designate likeor corresponding parts throughout the several views. It should beunderstood that the illustrations are for the purpose of describing apreferred embodiment of the inventions and are not intended to limit theinventions thereto.

FIG. 1 provides the general scheme of the electrical infrastructure ofthe present inventions. Each solar collector has junction box, with eachjunction box wired to a central combiner box via wire harness 10. Thecentral combiner box bundles the output into trunk 15, which goes intothe master fuse box. Electricity from the master fuse box travels to theinverter, then transformer, then power line.

Referring to FIG. 2, wire harness 10 is constructed of a plurality ofjoints, potentially including tee joint 20, cross joint 22 and/or yjoint 24 (not shown in

FIG. 2). The joints are connected one to another via insulated wire 30,and include female connector 26 or male connector 28 at variousjunctions. It should be understood that a multitude of electricalconfigurations may be achieved by varying the number and choice ofconnectors and joint types, and that FIG. 2 merely represents thepreferred configuration for coupling a plurality of junction boxes to acombiner box.

Tee, cross and y joints of FIGS. 3, 4, and 5 respectively areconstructed similarly with respect to each other, but vary according toshape and function. Using tee joint 20 as an example, joints comprisespokes 58 protruding from central hub 56, terminating in femaleconnector 26 or male connector 28. Length of spokes 58 may be elongatedby including longer lengths of insulated wire 30. Central hub 56includes external tee encasement 60, which defines channels 54 (bestshown in FIG. 6) through which insulated wire 30 protrudes outwardly(best shown in FIG. 2). Outwardly protruding insulated wire 30 may notbe visible if connector 26, 28, which is attached to insulated wire 30,abuts channel, as shown in FIG. 3. External tee encasement 60 preferablydefines securing apertures 52 through which zip ties or other fastenersmay be employed to secure tee joint 20 or wire harness 10 to preventunwanted movement during or subsequent to installation. Also,informational window 45 is preferred for displaying manufacturer, partnumber, technical specifications and the like.

Beneath tee encasement 60 lies sealed wire 38, which collectivelyincludes segments of exposed wire 34, portions of which are welded wire36, covered in sealant 40. This construction is best exemplified in thescheme set forth in FIG. 9 wherein it should be understood thatencasement 50 is depicted, but similar construction applies employingtee encasement 60, cross encasement 62 or y encasement 64.

Referring specifically to FIG. 9A, tee joint 20 is constructed by takingtwo separate insulated wires 30, and stripping off a portion ofinsulation 32 to reveal exposed wire 34, as shown in FIG. 9B.Preferably, the trunk wire would be window stripped to expose aninternal section of wire, whereas a branch wire would be end stripped.Preferably insulated wire 30 includes copper, and most preferably is a8, 10 or 12 AWG photovoltaic wire which is certified by UL and/or TUVfor use with solar applications to carry DC current up to 1000V. Abranch wire may be the next smaller size of wire as it will not carry asmuch current. Preferably insulation 32 is constructed of crosslinkedpolyolefin copolymer and is 1.7 mm thick. One preferred example of acommercially available and suitable insulated wire 30 is Betaflam Solarfrom Leoni Studer AG of CH-4658 Daniken, Switzerland. As shown in FIG.9C, exposed wires are resistance welded to form welded wire 36, with theend of the branch wire preferably welded to the center of the trunkwire. Resistance welding is preferably accomplished by using two copperelectrodes which pass a high current through the joint causing the wiresto be fused to form a solid material at the joint.

Fused wires 36 and any remaining exposed wires 34 are completely coatedwith sealant 40, as shown in FIG. 9D. Preferably sealant 40 is asynthetic rubber, more preferably a silicone-based rubber sealant, withPlasti Dip® multi-purpose rubber coating from Plasti Dip Internationalof Blaine, MN being the most preferred. Preferably sealant 40 is appliedwith a small brush, in a volume adequate to cure at a thickness ofapproximately 20 mils. Sealant 40 is permitted to completely cure,preferably at room temperature for approximately 4 hours. Once cured,the assembly is placed in a mold according to methods known in the art,and overmolded to form encasement 50, as shown in FIG. 9E. Encasement 50is preferably formed using a polypropylene material, most preferablyincluding a UV stabilization agent. The preferred polypropylene materialis RTP 199 from RTP Imagineering Plastics of Winona, Minn.

Slight modifications would be necessary to form cross or y joints 22 and24, particularly with respect to stripping and fusing wire. Moreover,additional steps would be required to secure female and male connectors26 and 28 to segments of insulated wire 30. Namely, the wire will becut, stripped and terminated with the applicable terminal, then a rubberboot will be installed to insulate the terminal. As assembled, allelectrically live components of wire harness 10, including insulatedwire 30, exposed wire 34, sealed wire 38 and connectors 26, 28 are allin electrical communication one with another.

In use, an installer would simply select the proper wire harness 10,preferably based on labeling or packaging, and connect the appropriateparts (ie female connectors 26 to junction boxes of solar collectors,and male connector 28 to combiner box). Wire harnesses of popularspecifications can be manufactured in bulk, or specially assembled inadvance if lesser quantities are required, or constructed on site asrequired by employing pre-assembled joints 20, 22, 24, connectors 26, 29and insulated wire 30.

In addition to the novel construction and substantial savings withrespect to materials, know-how and labor, the present inventions provideexceptionally low leakage compared to conventional solar connectors.Specifically, both the

MC Solarline 1 connector from Multi-Contact AG of Stockbrunnenrain,Switzerland, and the Solarlok connector of Tyco Electronics in Speyer,Germany, leak 1 mA (milliamp). In contrast, tee, cross and y joints 20,21 and 24 of the present inventions leak less than 50 nA (nanoamps).This is well below the maximum industry standard of 50 mA, as set forthby the solar industry leader.

Certain modifications and improvements will occur to those skilled inthe art upon a reading of the foregoing description. It should beunderstood that all such modifications and improvements have beendeleted herein for the sake of conciseness and readability but areproperly within the scope of the following claims.

I Claim:
 1. A low leakage electrical joint, said joint comprising: a. afirst exposed portion of a first insulated wire welded to a secondexposed portion of a second insulated wire; and b. an overmoldedpolypropylene encasement surrounding said weld, said encasementincluding a plurality of protrusions and defining at least one securingaperture positioned at the vertex of two of said protrusions.
 2. Thejoint of claim 1 wherein said first insulated wire includes copper. 3.The joint of claim 2 wherein said first insulated wire is capable ofcarrying DC current up to 1000V.
 4. The joint of claim 1 wherein atleast one of said insulated wires is a photovoltaic wire.
 5. The jointof claim 1 wherein said encasement includes a UV stabilization agent. 6.The joint of claim 1 wherein said encasement is molded in a shapeselected from the group consisting of T-shaped, cross-shaped andY-shaped.
 7. The joint of claim 1 wherein said securing aperture issemi-circular.
 8. The joint of claim 1 wherein said encasement definesat least one channel, said first insulated wire protruding outwardlyfrom said encasement through said channel.
 9. A wire harness, saidharness comprising: a. at least one joint comprising a first exposedportion of a first insulated wire welded to a second exposed portion ofa second insulated wire; and an overmolded polypropylene encasementsurrounding said weld, said encasement including a plurality ofprotrusions and having a profile selected from the group consisting ofT-shaped, cross-shaped and Y-shaped; and b. at least one femaleconnector attached to said first insulated wire.
 10. The wire harness ofclaim 9 wherein said insulated wire comprises at least one photovoltaicwire.
 11. The wire harness of claim 10 wherein the gauge of saidphotovoltaic wire includes at least one gauge selected from the groupconsisting of 8, 10, and 12 AWG.
 12. The wire harness of claim 9 furthercomprising at least one male connector in communication with said secondinsulated wire.
 13. A method of making an electrical joint comprisingthe acts of: a. stripping a portion of insulation off a first insulatedwire to form a first exposed portion; b. stripping a portion ofinsulation off a second insulated wire to form a second exposed portion;c. forming a fused portion by fusing said first exposed portion to saidsecond exposed portion; d. covering said fused portion, said firstexposed portion and said second exposed portion in sealant; e. curingsaid sealant; and f. enclosing said sealant in an encasement.
 14. Themethod of claim 13 wherein covering said fused portion includes the actof applying a synthetic rubber sealant.
 15. The method of claim 13wherein enclosing said sealant in an encasement includes the act ofmolding said encasement.
 16. The method of claim 13 further includingthe non-sequential act of attaching a female connector to said firstinsulated wire.
 17. The method of claim 16 further including thenon-sequential act of attaching a male connector to be in communicationwith said second insulated wire.